Stanley TT46 User Manual

Download

Page 1

Nuerenberg, David

Directive/Standards

No.

Approved body

EN ISO

28927-10

13732-1

Self

Infrastructure

Safety, Operation & Maintenance

TT46 Hydraulic Tie Tamper

60685 User Manual 12/2018 Ver. 20

DECLARATION OF CONFORMITY ÜBEREINSTIMMUNGS-ERKLARUNG DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD DICHIARAZIONE DI CONFORMITA

______________________________________________________________________

I, the undersigned: Ich, der Unterzeichnende: Je soussigné: El abajo firmante: lo sottoscritto:

hereby declare that the equipment specified hereunder: bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät: déclare que l’équipement visé ci-dessous: Por la presente declaro que el equipo se especifica a continuación: Dichiaro che le apparecchiature specificate di seguito:

Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombr e y apellido/Cognome e nome

1. Category: Kategorie: Catégorie: Categoria: Categoria:

2. Make/Marke/Marque/Marca/Marca

3. Type/Typ/Type/Tipo/Tipo: TT46133

4. Serial number of equipment: Seriennummer des Geräts: Numéro de série de l’équipement: Numero de serie del equipo: Matricola dell´attrezzatura:

Has been manufactured in conformity with Wurde hergestellt in Übereinstimmung mit Est fabriqué conformément Ha sido fabricado de acuerdo con E’ stata costruita in conformitá con

Richtlinie/Standards Directives/Normes Directriz/Los Normas Direttiva/Norme

Machinery Directive EN ISO EN ISO

5. Special Provisions: None Spezielle Bestimmungen: Sound Power Level: 108.9 dBA Dispositions particulières: Vibration Level: 7.7 m/s² Provisiones especiales: Disposizioni speciali:

6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.

Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione

Done at/Ort/Fait à/Dado en/Fatto a Stanley Infrastructure, Milwaukie, Oregon USA Date/Datum/le/Fecha/Data 4-23-2018

Signature/Unterschrift/Signature/Firma/Firma

Position/Position/Fonction/Cargo/Posizione North America Quality Manager

Nr Numéro No n.

2006/42/EC 3744 (15744) 11148-4, Cl. 5.5

Tie Tamper, Hydraulic

Stanley

All

Prüfung durch Organisme agréé Aprobado Collaudato

Self Self Self

Page 2

2 | TT46 User Manual

Page 3

(b)

(a)

TT46 User Manual | 3

Page 4

46 47

910

56 57

4 | TT46 User Manual

Page 5

TT46 Parts Illustration - Detail E

ITEM P/N DESCRIPTION

1 04374 Locknut

2 28494 Top Plate

3 20511 Lever

4 02494 Handle Grip

5 28369 Handle

6 20500 Spirol Pin

7 20498 Spring

8 20508 Pivot Screw

9 07493 Charge Plug

10 20499 Charge Valve

11 20505 Handle Pivot

12 58529 Trigger Handle

13 20502 Trigger

14 04056 Rod Wiper*

15 20515 Valve Spool

16 04058 Valve Spring

17 28322 CE Decal (TT46133)

18 11206 Circuit Type “C” Decal (TT46133)

19 12832 Orifice Plug (TT46133, TT46133B, TT46133C,

TT46133UP)

20 56725 Parker Hose Assembly

66727 Aeroquip Hose Assembly (TT46133B)

21 03972 Parker Female Coupler

81158 Stucchi Female Coupler

22 03973 Parker Male Coupler

81159 Stucchi Male Coupler

23 20517 Side Rod

24 74679 Name Tag

74680 Name Tag (TT46233)

25 72919 Snap-on Filler

26 25304 Cap Screw

27 04386 Cup Seal*

28 04780 Washer

29 04387 Rod Wiper*

30 02022 O-Ring*

31 31955 Lower Body

65046 Lower Body (TT46233)

32 15400 Hex Bushing

33 38008 Bit Guide Pair

34 32258 Bit Keeper

35 12148 Spring

36 12307 Nut

37 74832 STANLEY Logo

38 73680 Railroad Help Desk Decal

39 11588 Accumulator Valve Block

40 11212 Sound Power Level Decal (TT46133)

41 28409 Composite Decal

42 07479 Accumulator Diaphragm

43 04057 Bushing

TT46 Parts Illustration - Detail E

ITEM P/N DESCRIPTION

44 00293 O-Ring*

45 01362 O-Ring*

46 04381 Backup Ring*

47 04379 O-Ring*

48 04378 Porting Block

49 02900 Roll Pin

50 07480 Automatic Valve Body

04380 Automatic Valve Body (TT46233)

51 04605 Push Pin

52 04571 Push Pin

53 04382 Automatic Valve

54 12833 Piston

04385 Piston (TT46233)

55 07485 Flow Sleeve

04384 Flow Sleeve (TT46233)

56 04381 Backup Ring*

57 04379 O-Ring*

58 04383 Flow Sleeve Tube

59 44937 Tie Tamper Bit (not shown)

SK 04595 Seal Kit (*In seal kit)

Safety Precautions

The Safety Alert Symbol alerts you to potential personal injury hazards. Obey all safety messages that follow to avoid possible injury or death.

Indicates an imminently hazardous situation which will result in death or serious injury.

Indicates a potentially hazardous situation which could result in death or serious injury

Indicates a potentially hazardous situation which could result in property damage.

Always observe safety symbols. They are included for your safety and for the protection of the tool.

WARNING: Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in tool damage and/or serious injury.

WARNING: To reduce the risk of injury, read the instruction manual.

General

• Do not discard safety instructions. Give to the operator.

• This tool will provide dependable service if operated in accordance with the instructions given in this manual. Read and understand this manual and any stickers and tags attached to the tool and hoses before operation. Failure to do so could result in personal injury or equipment damage.

• Inspect the tool before each use and ensure all decals are legible. Contact STANLEY if replacements are needed.

• Establish a training program for all operators to ensure safe operation. Do not operate the tool unless thoroughly trained or under the supervision of an instructor. Keep out of the reach of children.

• Operators and maintenance personnel shall be able to physically handle the bulk, weight and power of the tool.

• Avoid unsuitable postures as these positions do not allow for counteracting of normal or unexpected movement of the tool, such as

TT46 User Manual | 5

Page 6

a sudden break of the tool bit. Change postures during extended tasks

Protection

Wear a Mask

to help avoid discomfort or fatigue.

• Do not operate a damaged, improperly adjusted, modified or incompletely assembled tool.

• Use and maintain the tool as stated in this manual. Misuse of the tool can cause serious injury. Do not modify the tool in any way.

• Do not operate the tool in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

• Provide adequate ventilation in closed areas when operating a gas or diesel hydraulic power source.

• Do not inspect, carry, clean, change accessories or perform maintenance on the tool while the power source is connected. Accidental engagement of the tool can cause serious injury.

• Ensure work piece is securely fixed. Be aware that failure of the work piece or accessories may generate high velocity projectiles.

• Stay alert, watch what you are doing and use common sense when operating a hydraulic tool. Do not operate this tool if you are tired or under the influence of drugs or alcohol. A moment of inattention while operating hydraulic tools may result in serious injury.

• During operation, do not contact mechanisms, accessories or hardware as they can become very hot or sharp; use your Personal Protection Equipment (PPE).

• Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations.

• Never operate the tool if you are unsure about the presence of underground utilities, such as electrical cables, gas pipes, etc. These can cause a hazard if damaged with the tool.

• The tool is not insulated against coming into contact with electric power. Use hose certified as non-conductive.

• Do not overreach. Maintain proper footing and balance at all times when using the tool.

• Slips, trips and falls are major causes of workplace injury. Be observant of hoses or oil surfaces lying about the work area, as they can be a tripping hazard.

• Operators must start in a work area without bystanders and must assess the risks to bystanders.

• Operators must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.

• Only use clean hydraulic fluid, filling equipment and lubricants that have been recommended by STANLEY.

• Ensure tools are working properly and safely by performing preventative maintenance (PM) procedures.

• Repair and service of this tool must only be performed by an authorized and certified dealer.

• Do not force the tool to do the work of a larger tool. Use the correct tool for your application.

• Use only hoses and hose couplings that are rated for a minimum working pressure of 2500 PSI (172 BAR).

• In spite of the application of relevant safety regulations and the implementation of safety devices, certain residual risks cannot be avoided. These risks are: repetitive strain injury due to incorrect posture and risk of pinching fingers when changing tool bit.

Dust and Fumes

• WARNING: Some dust created by power sanding, sawing, grinding,

drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints,

• crystalline silica from bricks and cement and other masonry products, and

• arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. Protect yourself and those around you. Research and understand the materials you are grinding. Follow correct safety procedures and comply with all applicable national, state or provisional health and safety regulations relating to them, including, if appropriate arranging for the safe disposal of the materials by a qualified person.

• When dust or fumes are created, control them at the point of emission. Direct tool exhaust to minimize disturbance of dust.

• Operate and maintain the tool as recommended in this manual to minimize dust.

• Use respiratory protection in accordance with employers instruction or as required by occupational health and safety regulations.

• Avoid prolonged contact with dust. Allowing dust to get into your mouth, eyes or lay on the skin may promote absorption of harmful chemicals.

PPE

• Always wear safety equipment such as impact resistant goggles, ear protection, head protection, breathing protection and safety shoes at all times when operating the tool.

• Hands may be exposed to hazards, impacts, cuts, abrasions and heat. Wear gloves.

• Wear a hardhat if performing overhead work.

• Use PPE that conforms to standards ANSI Z87.1 (Eye and Face Protection), ANSI Z89.1 (Head Protection), ANSI Z41.1 (Foot Protection) and ANSI S12.6 (S3.19) (Hearing Protection).

• Do not wear loose fitting clothing or jewelry when operating the tool.

M003

Wear Ear

M004

Wear Eye

M016

Sound

• Exposure to high noise levels can cause permanent, disabling hearing loss and other problems, such as tinnitus (ringing, buzzing, whistling or humming in the ears). Use hearing protection in accordance with employer’s instructions and as required by occupational health and safety regulations.

• Use and maintain as recommended in the manual to prevent an unnecessary increase in noise levels.

Vibration

• When using a non-rotary percussive tool to perform work related activities, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the body.

• If you experience numbness, tingling, pain or whitening of the skin in your fingers or hands, stop using the tool. Tell your employer and consult a physician.

• Wear warm clothing when working in cold conditions and keep your hands warm and dry.

• Exposure to vibration can cause disabling damage to the nerves and blood supply of the hands and arms.

• Use and maintain as recommended in the manual to prevent an unnecessary increase in vibration.

• Check for vibration level before each service. If you feel a higher than normal vibration, contact your STANLEY dealer for repair.

Hydraulic

• Warning: Hydraulic fluid under pressure could cause skin injection

injury. If you are injured by hydraulic fluid, get medical attention immediately.

• Do not let hydraulic oil get on the skin. Hydraulic oil is hot. Wear Personal Protection Equipment (PPE) at all times.

• Do not exceed the maximum relief valve setting stated on the tool.

• Inspect and clean couplers before use, daily. Replace damaged couplers immediately.

• Hydraulic circuit control valve must be OFF before coupling or uncoupling tools. Failure to do so may damage the couplers and cause overheating of the hydraulic system.

• Ensure the couplers are properly connected and are tight.

• Do not operate the tool at fluid temperatures above 140°F (60°C). Higher temperatures can cause operator discomfort and damage to the tool.

• Do not exceed the rated flow and pressure as stated on the tool. Rapid failure of the internal seals may result.

6 | TT46 User Manual

Page 7

What is the TT46 Hydraulic Tie Tamper?

TT46 is a hand held hydraulic tool used to compact railroad ties. TT46 requires an external hydraulic power supply capable of supplying 4-6 GPM or 7-10 GPM, depending on model.

Specifications

Pressure 1500-2500 PSI (103-172 BAR)

Flow 4-6 GPM (15-23 LPM) (TT46133 Models)

Max. Pressure 2500 PSI (172 BAR)

Max. Relief Pressure 2200-2300 PSI (152-159 BAR)

Recommended Back Pressure

Couplers 3/8 inch NPT flush face

Port Size SAE -8 O-ring

Tool Weight 63 Lbs (29 Kg)

Tool Length 39 inches (99 cm)

Width (at handles) 18 inches (46 cm)

Max. Hydraulic Oil Temp. 140 °F (60°C)

HTMA/EHTMA Category Type 1, Category C

7-10 GPM (26-38 LPM) (TT46233 Models)

250 PSI (17 BAR) or less

Do not install or change tool accessories while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury. Disconnect the hydraulic power source before installing or changing accessories.

1. Ensure the hydraulic power source is turned off and is disconnected from the tool.

2. Remove the cap screws holding the springs and bit keeper in place.

3. Remove the bit keeper and the bit guide.

4. Insert a tool bit into the bit keeper.

5. Attach the bit guide to the tool bit.

6. Insert the tool bit into the hex bushing. Match the bit hex pattern with the bushing hex pattern and ensure the bit slides into the hex bushing.

Note: Never use a blunt tool bit as they cause more vibration.

7. Reattach the bit keeper and springs.

Note: Never use TT46 unless the tool bit is locked in the retainer.

Tool Operation - Detail C

Note: Ensure hydraulic oil is at or above 50°F before using the tool. Preheat if necessary.

Sound & Vibration Declaration

Measured A-Weighted sound power 108.9 dBA

Uncertainty 3.39 dBA

Measured A-Weighted Sound Pressure 100.9 dBA

Uncertainty 3.39 dBA

Values determined according to noise test code given in ISO 15744, 11203 and 3744. Test conducted by independent notified body to comply with 2000/14/EC:2005.

TT46 Trigger Handle

Measured Vibration Emission Value: 3-Axis 7.7 m/sec²

Uncertainty 1.25 m/sec²

TT46 Non-Trigger Handle

Measured Vibration Emission Value: 3-Axis 7.4 m/sec²

Uncertainty 1.25 m/sec²

Parts of TT46 - Detail A

1 Trigger

2 Handles

3 CE Decal (CE Models)

4 Circuit Type “C” Decal (CE Models)

5 STANLEY Logo Decal

6 Tool Bit

7 Tool Name Tag

8 Accumulator Charging Port

9 Hydraulic Input and Output Ports

10 Bit Keeper

11 Railroad Help Desk Decal

12 Model & Serial Number

13 Sound Power Level Decal (CE Models)

14 Composite Safety Decal (CE Models)

Install Tool Bit - Detail B

TT46 will rise quickly when first turned on. Do not stand over or place any part of your body on top of the tamper. Wear safety shoes.

1. Ensure the hydraulic power source is turned off.

2. Wipe the hydraulic couplers clean and connect to the hydraulic power source.

3. Power up the hydraulic power source.

4. Wrap hands around the tool handles and place the tamper bit on the tie to be compacted, at a 90° angle. Apply down pressure.

Note: Maintain a balanced body position and secure footing while operating tool.

5. Slowly squeeze the trigger to start compacting. Squeeze harder for fast speed operation. Guide the tamper using both hands on the handles.

Note: Hold the tool correctly and be ready to counteract normal or sudden movements. Have both hands available.

6. Release the trigger to immediately stop the tool.

Note: If you encounter a breakdown or the tool stops for any reason, release the trigger and power down the hydraulic power source.

Tool Maintenance

Use only accessories, consumables and parts recommended by STANLEY.

Daily Maintenance

1. Remove hydraulic power from the tool and check all hydraulic connections and hoses for damage. Replace damaged parts before operating the tool.

2. Check the flow and pressure of the hydraulic power source using a calibrated flow meter. Proper flow and pressure maintain proper tool speed. If tool speed increases or decreases, stop using the tool and ensure proper flow and pressure.

3. Inspect the tool bit retaining parts. Replace when they have become worn, cracked or distorted.

4. Inspect tool to ensure all stickers are legible. Contact STANLEY if replacements are needed.

Accumulator Charge - Detail D

Check accumulator charge every 6 months or if poor performance develops.

Required Tools:

• STANLEY Accumulator Charge Kit (P/N 31254)

• Nitrogen Bottle

Check

1. Remove the charging plug from the TT46 handle.

2. (a) Hold the chuck end of the tester and (b) twist the gauge counter-

TT46 User Manual | 7

Page 8

clockwise. This will retract the valve stem.

3. Screw the tester onto the breaker charging port. Twist the tester gauge clockwise and read the pressure indicated on the gauge. Charge should be 500-600 PSI (34-41 BAR).

Charge

4. Retract the tester valve stem.

5. Connect the charging assembly hose to the tester.

6. Twist the tester gauge clockwise to advance the valve stem.

7. Slowly open the snub valve and charge to 600-700 PSI (41-48 BAR).

8. Close the snub valve, retract the tester valve stem and remove the tester from the breaker charging port. Replace the charging plug.

Troubleshooting

Problem Possible Cause Solution

Ensure the power source

The hydraulic power source is not running or not running properly.

is delivering proper flow and pressure. See “Specifications” on page 7. Proper flow and pressure maintain proper tool speed. Check regularly.

Tool Storage

Clean the tool and store in a clean, dry space that is safe from damage. Ensure the tool is secured and will not move during transport. An unsecured tool could cause injury or damage to the tool.

Tool Disposal

Hydraulic Oil

Hydraulic oil can contaminate the air, ground and water if not properly recycled. Recycle hydraulic oil in accordance with all State, Federal and local laws, at your local oil recycling facility.

Hydraulic Hoses

Hang hydraulic hoses to drain. Collect the oil for recycling. Contact your local municipal recycling authorities for an approved hydraulic hose recycling site.

Tool Body

Drain hydraulic oil from the tool, making sure to collect the oil for recycling. Discharge the accumulator, disassemble the tool and dispose of all non-metal parts. Recycle the metal components. Contact your local municipal recycling authorities for recycling instructions.

Accessories

4 inch steel with “V” cut (18 inch overall length) 44979

4 inch steel with “V” cut, Heavy Duty (18 inch overall length) 59034

4 inch steel with “V” cut (21 inch overall length) 44937

4 inch steel with “V” cut, Heavy Duty (21 inch overall length) 59033

4 inch steel (24 inch overall length) 33200

Anti-Vibration Handle Conversion Kit 27680

Service Tools

Tamping sleeve tool 01120

O-ring tool kit 04337

Seal kit 04595

Flow sleeve removal tube 04910

Flow sleeve removal tool 04919

Accumulator cylinder puller 05640

Accumulator tester 02835

Accumulator charge kit 31254

Charging assembly 15304

Flow and pressure tester 04182

Tool does not run or runs improperly.

Couplers or hoses are blocked.

Low accumulator charge pressure.

Hydraulic oil is above the max. operating temperature of 140°F (60°C).

High Back Pressure.

Mechanical failure.

Turn off and disconnect the tool from the hydraulic power source. Inspect and ensure no blockage exists.

Check accumulator charge. Recharge if necessary. See “Accumulator Charge Detail D” on page 7.

Provide an oil cooler to maintain proper oil temperature.

Check the hydraulic system for excessive back pressure.

Contact your STANLEY dealer for service.

8 | TT46 User Manual

Page 9

TT46 User Manual | 9

Page 10

Page 11

Page 12

STANLEY Infrastructure

6430 SE Lake Road, Portland, Oregon 97222 USA

(503) 659-5660 / Fax (503) 652-1780

www.stanleyinfrastructure.com

New Britain, CT 06053 USA